Method for sulphurizing a UO2 powder and method for making nuclear fuel pellets based on UO2 or mixed oxide (U,Pu)O2 oxide with added sulphur

ABSTRACT

Sulphidation method for a UO 2  powder, in which said powder is sulfurated by bringing it into contact with a gaseous sulphidation agent. 
     Method for manufacturing nuclear fuel pellets based on uranium oxide, or mixed oxide of uranium and plutonium, from a load of totally or partially sulfurated UO 2  powder or UO 2  powder and PuO 2  powder, by lubrication, pelletizing and sintering, in which: the load of powder subjected to the lubrication, pelletizing and sintering is prepared by the following successive steps:
         sulphidation of a UO 2  powder by the above sulphidation method;   optionally mixing, said sulfurated powder in a matrix comprising a UO 2  powder, or of a UO 2  powder and a PuO 2  powder;   and, subjecting said load, formed from said sulfurated powder or said mixture, to lubrication, pelletizing and sintering operations.

The present invention concerns a sulphidation method for a UO₂ powder.

The present invention further concerns a method for manufacturing nuclear fuel pellets based on uranium dioxide or MOX type mixed oxides of uranium and plutonium, based on mixed oxide (U, Pu)O₂ that may be used in any type of reactor, particularly in water nuclear reactors and, in particular, in pressurised water reactors.

More precisely, the invention concerns a method that makes it possible to obtain, by addition of sulphur, sintered nuclear fuel pellets with improved properties with regard to the microstructure of said pellets with, in particular, an increase in the size of the particles of material, compared to the normal sizes.

Among the methods used until now for the manufacture of nuclear fuel pellets based on mixed oxide (U, Pu)O₂, the document “Techniques de l'Ingénieur—Génie Nucléaire—B 3630-1 to 3630-10” teaches a method in which one starts with a mixture of UO₂ and PuO₂ powders that one subjects to grinding, compacting and granulation followed by pelleting and sintering (FIG. 1).

In said method, called “cobroyage direct” (direct co-grinding), which is shown schematically in FIG. 1, one starts with UO₂ and PuO₂ powders, which one mixes in the desired proportions in order to obtain the desired level of plutonium, taking account of the isotopic characteristics and the metal-oxide ratios of the different batches of powders used. Consequently, in the first dosage step, one mixes the desired quantities of UO₂ and PuO₂ powders in order to obtain the specified plutonium level. One then carries out the second step, which is a grinding step in cylindrical jars containing hard milling balls to break down the powder agglomerates, thoroughly mixing the constituents and fragmenting the particles of powder by thus increasing their suitability to sintering. One then carries out the third step of granulation, which consists in compacting the powders obtained previously, then splitting up the compacts obtained in a crusher and sieving them in order to obtain the desired particle size and transform the powder into a denser and roughly spherical product. After this operation, one carries out the lubrication step which consists in adding a lubricant such as zinc or calcium stearate to the granules. One then carries out the pelletisation by pressing the granules at constant pressure in alternating or rotating presses, then one proceeds to sintering in order to increase the density of the pellets and obtain the final characteristics.

Said method has the major disadvantage of providing nuclear fuel pellets in which the internal structure does not confer them with satisfactory suitability for precision grinding due to fissuring and appearance defects.

Furthermore, the sintered pellets obtained in this manner, although they meet the required specifications, still pose certain problems in subsequently obtaining the complete dissolution of the plutonium during reprocessing operations for irradiated pellets. Indeed, in a nuclear reactor, said pellets are subjected to high temperatures, which leads to the production of refractory plutonium oxide which is difficult to dissolve.

Patent FR-A-2 622 343 describes a method called “procédéde double cobroyage” (double co-grinding method) which constitutes an evolution of the previous method and which is shown schematically in FIG. 2, and in which one subjects to pelletising, then sintering, a load of UO₂ and PuO₂ powders comprising particles with particle sizes less than or equal to 250 μm, which is prepared in the following manner: dosage of a first mixture of powders (masterbatch) with a level of plutonium higher than the specified level and composed of UO₂, PuO₂ and, if appropriate, recycled powders which undergo a first grinding, then dosage of a second mixture of powder by addition of UO₂ and, if necessary, recycled powders. Said second mixture is subjected to a grinding for a limited period and sieving through a sieve with openings with dimensions less than or equal to 250 μm.

In a variant of said method, the second grinding is replaced by a simple mixing.

However, the pellets obtain either by the direct co-grinding method or the double co-grinding method, which meet the required specifications, do not have optimum characteristics vis-á-vis the release of fission gases, at high burn up rates.

However, it has been shown, for example in document FR-A-2 424 231, that the microstructure of the sintered pellets and in particular the size of the particles has a major effect on the exit velocity of the fission products, in particular gaseous products, during the irradiation of the fuels. Indeed, a particle size between 20 and 40 μm (microns) appears to favour the retention of fission gases while at the same time conserving in the material satisfactory flow characteristics.

It has also been taught by patent GB-A-2 019 824, corresponding to patent FR-A-2 424 231, that it is possible to prepare sintered uranium dioxide pellets comprising large particles. In the first step of the method, one reacts a uranyl nitrate with a source of sulphur in liquid form, only sulphuric acid being cited, at a high temperature to form a uranium trioxide containing sulphur. The UO₂ powder, obtained by precipitation and thermal treatment of the ammonium diuranate, makes it possible to form fuel pellets with particle sizes ranging from 50 to 1000 μm. The levels of elementary sulphur in the UO₂ may reach 300 ppm by weight.

In said method, the introduction of sulphur is achieved by liquid route, before the preparation of the UO₂ powder. Although this document highlights the influence of a sulfurated compound on the crystalline growth, the fact of carrying out the incorporation of sulphur in liquid form cannot suit the manufacture of MOX fuel, given the problems of criticality.

Moreover, the introduction of sulphur at a very upstream stage, that of preparing the UO₂ precursor, multiplies the number of steps where the sulphur is present, thus increasing the risks of pollution, corrosion, etc.

Japanese patent JP-A-62 115 398 describes the preparation of a nuclear fuel, in which one incorporates sulphur in the powder state in a powder of a single oxide chosen from among UO₂, ThO₂, PuO₂ and Gd₂O₃.

The operation is carried out by mixing the powder with 0.1% to 1% by weight of pure sulphur, or a sulfurated organic compound such as ammonium sulphate, napththylamine sulphonate or xylene sulphonic acid.

The tablets obtained are previously heated up to the melting point of the sulfurated additive, then sintered at 1500-1800° C. for 1 to 10 hours in a H₂ reducing atmosphere. No precise particle size is given in this document.

In this document, it is necessary to carry out a fusion step of the sulfurated additives, prior to the sintering operation.

The sulfurated organic compound has, it seems, the purpose of improving the retention of fission gases and the interaction between the pellet and the sheath.

The pellet obtained has a heterogeneous structure with particles of small diameter on the surface and large particles in the core of the pellet.

Document FR-A-2 738 076 describes a method for manufacturing MOX fuel pellets by incorporation in the initial powder of an organic wax of composition C₁₇H₃₇NO₃S, normally used for its anti-agglomeration properties. The mixture generally containing 0.6% by weight of additive is achieved by co-grinding, then forming and sintering. The sizes of the particles observed in the final pellets are between 20 and 40 μm, in other words they are higher, by a factor of 2 to 5, than the normal sizes. The authors indicate that said wax, which has a molar weight around 10 times higher than that of pure sulphur, makes it possible to intimately mix small quantities of sulphur.

There is a need for a method that makes it possible to obtain a fuel based on mixed oxide or uranium dioxide with large particle size which, in addition, meets all of the required specifications for these pellets.

There is also a need for a method for manufacturing pellets that does not have the limitations, defaults or disadvantages of the methods of the prior art, in which one uses a sulfurated additive in liquid or solid form.

The aim of the present invention is, in particular, to provide a sulphidation method and a method for manufacturing nuclear fuel pellets including this sulphidation treatment, which makes it possible to satisfy, among other things, the requirements defined above.

This aim and others are attained according to the invention by a sulphidation method of a UO₂ powder, in which said powder is sulfurated by bringing it into contact with a gaseous sulphidation agent.

Consequently, in a fundamental manner, the present invention introduces the production, by gaseous route, of sulfurated species in the UO₂ or UO₂ and, PuO₂ powder.

The sulphidation agent may advantageously be chosen from among carbon sulphide CS₂ and hydrogen sulphide H₂S.

The preferred sulphidation agent is hydrogen sulphide H₂S.

Advantageously, the gaseous sulphidation agent is mixed with hydrogen and an inert gas, such as argon or nitrogen.

Advantageously, the gaseous mixture generally comprises, by volume, 2.5% to 25% of sulphidation agent, such as H₂S, from 37.5% to 72.5% of hydrogen, and from 60% to 2.5% of an inert gas such as argon.

The total flow rate of gas, of the mixture of gas used for the sulphidation, is generally from 1 to 500 ml/min, for example close to 200 ml/min.

Bringing into contact the gaseous sulphidation agent is generally carried out at a temperature from 800° C. to 1200° C., and preferably from 970° C. to 980° C. for a period time of 1 to 11 hours.

This preferred temperature range is chosen for kinetic reasons, but lower temperatures would be suitable.

Said treatment leads to the production of powder containing sulphur in the UO₂ structure or in adsorption, as well as in the form of crystalline phases, particularly UOS.

The sulphidation method according to the invention differs fundamentally from the sulphidation methods of the prior art by the fact that the sulfurated species—which, in the method for manufacturing pellets is favourable to the growth of particles—is introduced by a gaseous route method during which the UO₂ powder is brought into contact with the sulphidation agent, such as H₂S, which is in the gaseous state.

In other words, the sulphidation of the uranium dioxide takes place under gaseous flow, for example hydrogen sulphide, and the sulphidation agent is therefore introduced neither in liquid form nor in solid form.

The mode of sulphidation by gaseous route with a sulfurated agent in gaseous state, such as H₂S, is neither described nor suggested in documents of the prior art.

The method according to the invention, in which the sulfurated additive or sulphidation agent is used in the gaseous form is a major security factor and makes it possible to avoid the risks of criticality linked to the addition of additive by liquid route, in particular, in the manufacture of UO₂-PuO₂ mixtures. Indeed, hydrogenated products, such as water, have a moderating effect, in other words they can favour a non-controlled chain fission reaction (criticality accident).

Another difference resides in the stage in which the sulphidation occurs during the preparation of the UO₂ powder for the method by liquid route, or during the manufacture of fuel for the method of this invention.

Compared to methods using the sulfurated additive by solid route, the advantages of using an agent in gaseous state are better control of the average sulphur level, in particular of the low levels, thanks to the adaptation of the thermal cycle (length, H₂S concentration, temperature) and to the better dispersion of the sulphur throughout the powder.

The sulfurated powder obtained has a well defined sulphur content, which may be easily adjusted.

The level of sulphur in the final powder is, in particular, a function of the thermodynamic and kinetic conditions of the sulphidation which may be easily adjusted in order to attain the desired level. Generally, the level of sulphur in the UO₂ powder is from 100 ppm to several %.

The invention further concerns a method for manufacturing nuclear fuel pellets based on uranium oxide, or mixed oxide of uranium and plutonium, from a load of totally or partially sulfurated UO₂ powder or UO₂ powder and PuO₂ powder, by lubrication, pelletizing and sintering, in which the load of powder subjected to said lubrication, pelletizing and sintering is prepared by the following successive steps:

-   -   sulphidation of a UO₂ powder by the method described above;     -   optimaly mixing said sulfurated powder in a matrix consisting of         a UO₂ powder, or of a UO₂ powder and a PuO₂ powder;     -   and, subjecting said load, formed from said sulfurated powder or         said mixture, to lubrication, pelletizing and sintering         operations.

This manufacturing method has all the advantages inherent in the use, during the method for sulphidation of the UO₂ powder and, in accordance with the invention, of a gaseous sulphidation agent.

Indeed, due to the use of a gaseous sulphidation agent for the sulphidation of the UO₂ powder, on thus obtains a sulfurated powder in which the sintering, alone, or incorporated in a matrix of UO₂ or UO₂ and PuO₂, leads in a surprising manner to a microstructure with large grains in the final pellets.

Without wishing to be linked to any theory, the invention uses the temporary presence of sulphur or uranium oxysulphide in the UO₂ or MOX structure during the sintering.

The sulphidation of the uranium dioxide according to the invention leads to, following sintering, to pellets that meet all the necessary requirements therefor.

In particular, the pellets prepared by the method according to the invention with sulphidation of the UO₂ powder by gaseous route have, for example, a microstructure generally characterised by a size gradient between the edge and the centre, and the presence of large grains at the core of the pellets, a density of around 97 to 98% of the theoretical density, and finally an extremely low level of residual sulphur, generally less than 20 ppm, or even 10 ppm.

Indeed, thanks to the incorporation of the sulphur by gaseous route, according to the invention, the quantity of species resulting from the sulphidation to be eliminated during sintering is limited to sulphur dioxide SO₂, unlike the incorporation method by solid route, which introduces organic species.

Said virtually complete elimination of the sulphur has a beneficial effect on the final properties of the pellets.

The sulfurated UO₂ powder is preferably incorporated into the matrix of UO₂ or UO₂ and PuO₂ by simple mixing, in an extremely simple manner, and consequently one easily obtains a perfectly homogeneous load of powder.

The level of sulphur in the load subjected to the lubrication, pelletizing and sintering operations is generally from 50 ppm to 1%, and preferably from 100 ppm to 1000 ppm (0.1%).

Preferably, all or part of the UO₂ powder or mixture of UO₂ and PuO₂ powders constituting the matrix has been, prior to lubrication, subjected to a grinding operation, preferably in a ball mill.

All or part of the UO₂ powder used in the constitution of the load may be a powder that has been subjected, prior to grinding, to a reducing treatment, for example under a hydrogenated argon atmosphere, so that it has an O/U atomic ratio of 2.00 to 2.04, for example of 2.04.

A pore forming agent may be incorporated in the load of powders during lubrication.

The pelletizing may in particular be carried out by means of a hydraulic press.

Advantageously, the sintering is carried out at a temperature, for example, between 1650° C. and 1750° C., preferably close 1700° C., in a hydrogenated atmosphere, for example hydrogenated argon. Preferably, the sintering atmosphere is humidified.

Finally, one may subject the sintered pellets to dry precision grinding.

Other characteristics and advantages of the invention will become clearer on reading the following description, given by way of illustration and in nowise limitative, and by referring to the appended drawings, in which:

FIGS. 1 and 2 already described are block diagrams showing the steps of conventionnal methods for manufacturing pellets, according to the prior art;

FIG. 3 is a graph showing the change in concentration C of sulphur (in ppm) as a function of the sintering temperature T, expressed in ° C.;

FIG. 4 is a microstructural observation, or micrograph, of a sintered pellet from a sulfurated mixture containing 270 ppm of S, consisting of UO₂ and UOS. The line shown represents 200 μm;

FIG. 5 is a microstructural observation, or micrograph, of a sintered pellet from a sulfurated mixture containing 270 ppm of S, consisting of UO₂ and UOS. The line shown represents 50 μm;

FIG. 6 is a microstructural observation, or micrograph, of a sintered pellet from a UO₂ powder without sulphur. The line shown represents 50 μm;

FIG. 7 is a microstructural observation, or micrograph, of a sintered pellet from a sulfurated UO₂ powder containing 1900 ppm of S. The line shown represents 50 μm;

FIG. 8 is a microstructural observation, or micrograph, of a sintered pellet from a sulfurated mixture containing 270 ppm of S, consisting of UO₂ and a sulfurated powder containing 1900 ppm of S. The line shown represents 50 μm;

FIG. 9 is a microstructural observation, or micrograph, of a sintered pellet from a sulfurated mixture of UO₂ and PuO₂ containing 270 ppm of S, consisting of UO₂, PuO₂ and UOS. The line shown represents 50 μm;

FIG. 10 is a microstructural observation, or micrograph, of a sintered pellet from a mixture of UO₂ and PuO₂ without sulphur. The line shown represents 50 μm.

The sulphidation method, according to the invention, of a UO₂ powder consists in bringing into contact said powder with a gaseous sulphidation agent.

The uranium dioxide powder generally has an atomic ratio (O/U) of 2.0 to 2.4.

If the uranium dioxide powder that one has available has too high a stoichiometric ratio, in other words if it has a higher O/U ratio, for example 2.04 to 2.25, one subjects it to a reduction treatment, generally under a hydrogenated argon atmosphere, at a temperature for example from 600° C. to 1000° C. that can bring back the O/U atomic ratio into the suitable range defined above.

The sulphidation agent is, according to the invention, a gaseous sulphidation agent under the treatment conditions.

The sulphidation agent is generally chosen from among carbon sulphide CS₂ and hydrogen sulphide H₂S.

The preferred sulphidation agent is hydrogen sulphide H₂S because H₂S is gaseous at ambient temperature, unlike CS₂ which is liquid.

Preferably, to carry out the treatment, the sulphidation agent is mixed with hydrogen and/or an inert gas such as argon or nitrogen.

The proportion, by volume, of the sulphidation agent is generally from 1% to 100% by volume of the gaseous mixture.

In the case of a gaseous mixture composed of hydrogen, an inert gas such as argon, and H₂S as sulphidation agent, the composition by volume of the mixture is generally from 2.5 to 25% of H₂S, from 37.5% to 72.5% of H₂ and from 60% to 2.5% of argon.

The sulphidation operation is, for example, carried out in a tubular quartz reactor heated by means of intensity regulated resistive windings, in which the powder to be sulfurated is put.

The reactor is equipped with regulation means making it possible to circulate a total flow rate of gas of between 1 and 500 ml/minute, for example 200 ml/min, as well as, if necessary, means of modifying the proportions of each of the gases in the mixture.

The sulphidation is generally carried out at a temperature of 800° C. to 1200° C. Preferably, the temperature is from 970° C. to 980° C. It has been observed that in kinetic terms, it is particularly interesting to operate in said temperature range but lower temperatures would also be suitable, for example from 800° C. to 950° C.

The treatment time is generally from 1 to 11 hours, for example 2 h 30 min.

The sulphidation treatment leads to the production of a powder containing variable levels of sulphur, which depends on the thermodynamic and kinetic conditions of sulphidation. The quantity of sulphur may, according to the invention, be easily adjusted, during the treatment, carried out preferably under a controlled carrier gas by acting on the various parameters governing the sulphidation, such as the temperature, flow rate and the composition of the gas flow and the duration of the treatment.

The concentration or level of sulphur in the final sulfurated powder is variable, but is generally from 100 ppm to 12% of sulphur.

The sulphur is present in the UO₂ structure or in adsorption, but it may appear in the form of crystalline phases such as UOS, US or US₂.

Since the proportion and the nature of the phases are linked to the level of sulphur, during the sulphidation, one seeks to avoid the formation of US and US₂, by aiming for low, but sufficient, sulphur concentrations in order to obtain the desired effect by adjusting the sulphidation parameters mentioned above.

The invention further concerns a method for manufacturing nuclear fuel pellets based on uranium oxide or mixed oxide of uranium and plutonium (MOX), from a totally or partially sulfurated UO₂ powder or a UO₂ and PuO₂ powder, by a series of steps essentially comprising a pelletizing step and a sintering step.

Said method for preparing nuclear fuel pellets is characterised by the fact that all or part of said UO₂ powder used in the method for manufacturing pellets is sulfurated beforehand by the sulphidation method as detailed above.

The phrase “all or part of the UO₂ powder is sulfurated beforehand” is taken to mean that the sulfurated powder may either be pelletized and sintered alone, in other words constitute the whole of the load of powder subjected to the pelleting then sintering, or be introduced in a matrix of UO₂, or of a mixture of UO₂ and PuO₂.

It should be noted that the uranium dioxide powder used in the composition of the matrix is, in the present description, generally defined by the formula UO₂ in order to simplify matters, independently of any stoichiometric discrepancy.

Nevertheless, said uranium dioxide powder generally exhibits an over stoichiometry and consequently has in fact the formula UO_(2+x), where x=0 to 0.25.

It will be seen later that, preferably, the stoichiometry of the uranium dioxide must be low, for example where x is 0 to 0.04 and that, if necessary, one subjects the crude UO₂ powder to a reducing treatment in order to bring the stoichiometry into this range.

The incorporation in said matrix is carried out in the solid state, preferably by simple mixing, generally in a gentle mixer, for example an oscillating/rotating movement type mixer at a rotation speed generally from 15 to 90 rpm and for a period of time of 15 to 60 minutes.

Any other type of mixer may be used, particularly a conical screw mixer or a shovel mixer.

Said mixing step consists in fact in a simple mechanical mixing which turns out to be sufficient to obtain, after pelleting and sintering, fuel pellets that meet the necessary specifications and which have all of the improved properties characteristic of the pellets of the invention. The total or partial sulphidation of the UO₂ powder improves, particularly in the case of the preparation of mixed oxide pellets, the homogeneity of distribution of the plutonium within the mixture.

Since the sulphidation conserves the morphology of the UO₂ granules, all of the load intended for pelleting remains flowable, facilitating the filling of the matrices during the subsequent pressing step.

The mass percentage of sulfurated UO₂ powder compared to the whole of the mixture of powders depends on the nature of the sulfurated powder which may comprise UOS and/or US and/or US₂.

Consequently, in the case of a sulfurated UO₂ powder, consisting essentially a monophase of UOS, the level of sulfurated powder is generally from 0.1 to 10% by weight.

In all cases, the mixture is formed in such a way that the overall concentration by weight in elementary sulphur is generally from 270 ppm to 1%, in the final load (with a matrix of UO₂ or UO₂ +PuO₂). However, it is also possible to aim for lower levels, for example from 100 ppm to 270 ppm.

In the case of a matrix consisting solely of uranium dioxide powder UO₂, one uses for the matrix a UO₂ powder which is analogous to that used above as base product for the sulphidation.

The uranium powder incorporated into the matrix generally has an atomic ratio (O/U) of 2.0 to 2.04.

If the uranium dioxide powder that one has available has a too high stoichiometry, in other words with a higher O/U ratio, for example from 2.04 to 2.25, one may subject it to a reducing treatment in order to maintain the O/U atomic ratio in the suitable range defined above.

All or part of the UO₂ matrix may also advantageously consist of a UO₂ powder ground before the incorporation of the sulfurated uranium dioxide powder.

One then preferably uses as base powder a UO₂ powder with a high O/U ratio, for example from 2.04 to 2.25 and one subjects it to a grinding step in order to obtain a finer powder and to maintain the O/U ratio from 2.04 to 2.25.

Said grinding operation, known to those skilled in the art, is generally carried out in a ball mill (“broyeur àboulets”) with balls of a hard material or in any other type of grinder, for example a ball grinder (“broyeur àbilles”) (grinding by attrition) or a gas jet grinder.

In the case of a matrix consisting of a mixture of UO₂ and PuO₂ powders, all or part of the uranium dioxide powder may be a powder that originally had too high a stoichiometry and which has been subjected to a reducting treatment in order to bring the O/U atomic ratio into the suitable range defined above.

In addition, all or part of the mixture of UO₂ and PuO₂ powder forming the matrix may have undergone beforehand, and in an advantageous manner, a grinding under the conditions already described above for a matrix consisting solely of UO₂.

For example, part of the UO₂ powder mixed with the sulfurated UO₂ powder could be a UO₂ powder reduced under the conditions detailed above, whereas the matrix could consist of a mixture of UO₂ and PuO₂ powders that have been subjected to a grinding.

The PuO₂ powders may, if necessary, be calcinated before being introduced into the mixture.

The sulfurated and non-sulfurated UO₂ powders on the one hand, and the PO₂ powder, may be very precisely dosed in order to obtain, in the mixture subjected to pelleting, the exact specified level of plutonium in the final mixed oxide pellets. Said plutonium concentration is generally from 2 to 15% by weight.

The UO₂+PuO₂ matrix may be prepared, for example, as in document FR-A-2 738 076, and in particular as in steps a) to e) of claim 1 or a) and b) of claim 2.

The following steps of lubrication, with the addition if necessary of a pore forming agent, forming by pressing or pelletizing, sintering and, if necessary, precision grinding are carried out in a known manner such as, for example, in the prior patents described above.

The lubrication step may be carried out using, for example, as lubricant zinc or calcium stearate.

In the case where the density of the sintered pellets obtained from this load of powders is too high compared to the required specifications, one adds a pore forming agent to the powder, for example azodicarbonamide, at the same time as the lubricant.

The step of pelletizing or forming by pressing may be carried out, for example, using a hydraulic press.

At this stage, before sintering, the density of the pellets is generally from 50 to 60% of the theoretical density, which is 10.96 to 11.46.

The sintering step is carried as quickly as possible, after the pelleting, in such a way as to limit the effects of radiolysis of the lubricant and, if appropriate, the pore forming agent on the crude pellets.

The sintering is generally carried out, as in the prior art, at a temperature generally from 1650° C. to 1750° C., preferably close to 1700° C., in a reducing gas atmosphere, for example in a hydrogen—argon mixture.

Preferably, the sintering atmosphere is humidified.

The invention profitably employs the temporary presence of sulphur or uranium oxysulphide in the UO₂ structure or MOX, during the sintering. The degradation of the sulphur, by local humidity or by that in the sintering atmosphere at low temperatures, goes through the formation of gaseous sulphur oxide which is eliminated easily and simultaneously by the formation of UO₂.

It should be noted that in FIG. 3 the sulphur concentration (in ppm) drops with the sintering temperature.

It goes from 270 ppm in the initial sintering powder (“0° C.”) to around 10 ppm at 1700° C. after a levelling out period of 4 hours.

After sintering, one may subject the pellets to a precision grinding which may be carried out in a centreless grinding machine under dry conditions, in order to obtain pellets that meet the diameter specification.

The pellets obtained by the method according to the invention generally have the following characteristics:

-   -   a density of around 97 to 98% of the theoretical density,     -   a particle size gradient between the outer zone around 50 to 300         μm thick, and the core of the sintered pellet (FIG. 4). The         grain size is measured on micrographs obtained by optical         microscopy of the pellets, which have been previously sectioned,         polished and which have undergone a chemical attack. This type         of microstructure favours the reduction of mechanical         interactions between the pellets and the sheathes in which the         pellets are then introduced. At the edge of the pellets, the         grains have an average size of around 10 microns. The principal         zone has large grains,     -   a high grain size, at the core of the pellets, in which the         average value attains 25 to 30 μm (FIG. 5) compared to 8 to 10         μam for a sulphur-free fuel (FIG. 6). Some grains may measure         several tens of microns (80 μm) or even hundreds of microns (up         to 600 μm),     -   good homogeneity of the grain size distribution,     -   a residual sulphur level of 10 ppm by weight, to 20 ppm for         pellets with a higher initial concentration of sulphur. Most of         the sulphur is no longer in the structure before the start of         the sealing of the porosity of the fuel, i.e. around 1100° C.         (FIG. 4),     -   the addition of water, either via the sintering atmosphere, or         by reducing the over-stoichiometry of the matrices, in         particular of UO_(2+x), makes it possible to oxidise the sulphur         present into SO₂.

The following examples, given by way of illustration and in nowise limitative, illustrate the sulphidation method as well as the method for manufacturing nuclear fuel pellets according to the invention.

The comparative examples illustrate the preparation of pellets from powders that have not been subjected to the sulphidation treatment by gaseous route according to the invention.

EXAMPLE 1

a) Sulphidation Treatment

Firstly, one subjects a uranium dioxide powder to a thermal treatment at 970° C. for 2 h 30 min under a gas flow with a composition, by volume, of 5% H₂S-35% H₂-60% Ar.

Following this treatment, the powder consists of a UO₂ phase and traces of a UOS phase. Chemical assaying of elementary sulphur in said powder indicates an overall average level of 1900 ppm by weight of sulphur (equivalent to 1.7% by weight of UOS in the powder).

b) Preparation of the Pellets

The powder is then formed using a hydraulic press under a pressure of 300 MPa. During this step, the matrix is lubricated by means of zinc stearate. The crude tablets or pellets have cylindrical geometry characterised by a height and a diameter close to 6 mm.

The pellets obtained are then subjected to sintering at 1700° C. under argon atmosphere containing 5% hydrogen and humidified with 1000 ppm water.

The sintered pellets are characterised by:

-   -   a grain size gradient between the edge and the centre of the         pellets;     -   an average grain size at the core of the pellets of 25 μm and at         the edge of 10 μm. This microstructure is shown in FIG. 7. The         size of the large grains may attain 60 μm.     -   a residual sulphur level of between 10 and 20 ppm by weight.

EXAMPLE 1A (COMPARISON)

One prepares the pellets in the same way as in example 1, but from a uranium dioxide powder that has not been subjected to sulphidation treatment.

The powder pellets thus prepared, which have not undergone gaseous sulphidation treatment, have a significantly smaller average grain size, 11 μm, as illustrated in FIG. 6.

EXAMPLE 2

a) Sulphidation Treatment

One subjects a uranium dioxide powder to a thermal treatment at 980° C. for 11 hours under a gas flow with a composition, by volume, of 25% H₂S-72.5% H₂-2.5% Ar. Following this treatment, the powder comprises a monophase UOS. The theoretical concentration of elemental sulphur is 11.2%.

b) Preparation of the Powder to be Pelletized

One subjects 402 g of uranium dioxide powder, with an O/U atomic ratio of 2.18, to a grinding in a ball jar mill for 3 hours.

Following said grinding, the UO_(2+x) powder is mixed with 0.24% by weight of UOS obtained previously in a Turbula® type mixture at 62 rpm for 45 minutes. The overall concentration of elementary sulphur in said mixture is 270 ppm by weight.

c) Preparation of the Pellets

The mixture is formed using a hydraulic press under a pressure of 300 MPa. During this step, the matrix is lubricated by means of zinc stearate. The crude tablets have cylindrical geometry characterised by a height and a diameter close to 6 mm.

The pellets obtained are subjected to sintering at 1700° C. under argon atmosphere containing 5% hydrogen and humidified with 1000 ppm water.

The sintered pellets are characterised by:

-   -   a grain (particle) size gradient between the edge and the centre         of the pellets;     -   an average grain size at the core of the pellets of 27 μm and at         the edge of 10 μm. The size of the large particles may attain 80         μm. Said microstructure is shown in FIG. 5.     -   a residual sulphur level of 10 ppm.

EXAMPLE 3

a) Preparation of the Powder to be Pelletized

One subjects a uranium dioxide powder, with an O/U atomic ratio of 2.18 to a reducing treatment under hydrogenated argon atmosphere, bringing the final O/U atomic ratio to 2.04.

Following said treatment, the UO_(2.04) powder is mixed with the powder from the sulphidation treatment of example 1, with an elementary sulphur concentration of 1900 ppm by weight, in such a way that the final mixer has an elementary sulphur concentration of 270 ppm by weight. The mixing step is carried out in a Turbula® type mixer at 62 rpm for 45 minutes. The load comprises 85.8% by weight of uranium dioxide powder and 14.2% by weight of sulfurated powder.

b) Preparation of the Pellets

The mixture is formed using a hydraulic press under a pressure of 300 MPa. During this step, the matrix is lubricated by means of zinc stearate. The crude tablets have cylindrical geometry characterised by a height and a diameter close to 6 mm.

The pellets obtained are subjected to sintering at 1700° C. under argon atmosphere containing 5% hydrogen and humidified with 1000 ppm water.

The sintered pellets are characterised by an average grain size at the centre of the pellets of 27 μm (FIG. 8) and at the edge of 10 μm. The size of the large grains may attain 80 μm.

In addition to a microstructure with a size gradient between the edge and the centre, in addition to the presence of large grains at the core of the pellets, the method also makes it possible to obtain pellets with densities of around 97% to 98% of the theoretical density (10.96).

This final observation also applies to examples 1 and 2.

EXAMPLE 4

Illustration with PuO₂

a) Preparation of the Powder to be Pelletized

One subjects 367 g of a mixture consisting of 327 g of a uranium dioxide powder (O/U=2.18) and 40 g of a plutonium dioxide powder to a grinding in a ball mill for 2 hours.

Following said grinding, the mixture of the two uranium and plutonium oxides is sieved through a sieve with openings ≦250 μm, then mixed with the powder from the sulphidation treatment of example 2, with a concentration of elementary sulphur of 11.2% by weight, in such a way that the final mixture has a concentration of elementary sulphur of 270 ppm by weight. The mixing step is carried out in a mixer with a simple rotating movement at 60 rpm for 60 minutes. The load consists of 99.76% by weight of the mixture of two oxides of uranium and plutonium and 0.24% by weight of UOS obtained according to example 2.

b) Preparation of the Pellets

The mixture is formed using a hydraulic press under a pressure of 300 MPa. During this step, the matrix is lubricated by means of zinc stearate. The crude tablets have cylindrical geometry characterised by a height and a diameter close to 6 mm.

The pellets obtained are then subjected to sintering at 1700° C. under argon atmosphere containing 5% hydrogen and humidified with 1000 ppm water.

The sintered pellets are characterised by an average particle size at the centre of the grains of 20 μm (FIG. 9) and at the edge of around 5 μm. The size of the large grains may reach 60 μm.

EXAMPLE 4A (Comparison)

By way of comparison, the pellets of the mixture (UO₂+PuO₂) that has not been subjected to mixing with UOS lead to the microstructure shown in FIG. 10. The average measured grain size is 6 μm.

The sintered pellets have a density of around 96% of the theoretical density (11.01). 

1. A sulfidation method for a UO₂ powder comprising sulfurating the UO₂ powder by bringing the powder into contact with a gaseous sulfidation agent at a temperature from 800° C. to 1200° C. wherein the sulfidation agent comprises 2.5% to 25% of H₂S, from 37.5% to 72.5% of hydrogen, and from 60% to 2.5% of inert gas, and the sulfidation is carried out for a period of time of 1 to 11 hours.
 2. The method according to claim 1, wherein the inert gas is argon or nitrogen.
 3. The method acc6rding to claim 1, wherein the gaseous sulfidation agent with hydrogen and/or the inert gas has a total gas flow rate from 1 to 500 ml/mm.
 4. The method according to claim 3, wherein the gaseous mixture has a total gas flow rate of 200 ml/mm.
 5. The method according to claim 1, wherein the sulfurating is carried out at a temperature from 970° C. to 980° C. for a period of time from 1 to 11 hours.
 6. A method for manufacturing nuclear fuel pellets based on uranium oxide, or mixed oxide of uranium and plutonium, from a load of totally or partially sulfurated UO₂ powder or mixture of UO₂ powder and PuO₂ powder, the method comprising: (a) sulfurating a UO₂ powder by bringing the powder into contact with a gaseous sulfidation agent comprising H₂S, hydrogen and inert gas; (b) optionally mixing the sulfurated powder in a matrix comprising a UO₂ powder or comprising a UO₂ powder and a PuO₂ powder; and (c) subjecting the load of the sulfurated powder or of the mixture of the sulfurated powder and the matrix to lubrication, pelletizing and sintering operations, wherein the level of sulfur in the load subjected to the lubrication, pelletizing and sintering operations is from 50 ppm to 1%.
 7. The method according to claim 6, wherein the silfurated powder is incorporated in the matrix by simple mixing.
 8. The method according to claim 6, wherein the level of sulfur in the load subjected to the lubrication, pelletizing and sintering operations is fiom 100 ppm to 1000 ppm.
 9. The method according to claim 6, wherein all or part of the matrix subjected to the lubrication, pelletizing and sintering operations is subjected, prior to the lubrication operation, to a grinding operation.
 10. The method according to claim 9, wherein the grinding operation is performed in a ball mill.
 11. The method according to claim 6, wherein all or part of the UO₂ powder in the load is a powder that has been subjected, prior to grinding, to a reducing treatment such that the powder has an O/U atomic ratio of 2.00 to 2.04.
 12. The method according to claim 6, wherein a pore forming agent is incorporated in the load during lubrication.
 13. The method according to claim 6, wherein the pelletizing operation is canied out using a hydraulic press.
 14. The method according to claim 6, wherein the sintering operation is carried out at a temperature between 1650° C. and 1750° C. in a hydrogenated atmosphere.
 15. The method according to claim 14, wherein the sintering operation is carried out at a temperature of 1700° C. in a hydrogenated atmosphere.
 16. The method according to claim 14, wherein the atmosphere is humidified.
 17. The method according to claim 6, wherein the pellets produced are subjected to dry precision grinding. 